Chapter VI: Introduction (4)

The manufacture of _crucible_ or _cast steel_ has been carried on at Essen in Prussia by the firm of A. Krupp & Co., on a scale surpassing anything attempted elsewhere,—theirs being the largest steel-works in the world, and remarkable for the variety and excellence of its products. It began in so small a way that it is said only a single workman was employed. To the Great Exhibition of 1851, at London, Krupp’s firm sent a block of crucible cast steel weighing 2¼ tons, a larger mass of the metal than had ever been shown before, and looked upon with no little astonishment, for at that time steel was a precious commodity, the price of refined steel ranging from £45 to £60 per ton. At the next London Exhibition, in 1862, the Essen Works showed a block of cast steel 20 tons in weight, and at the Vienna Exhibition of 1873, one of 52 tons. This casting, which was first made of a cylindrical shape, was forged into an octagonal form under an immense steam-hammer, larger than the Woolwich hammer described on a previous page, for the weight of the moving part is no less than 50 tons. This huge mass of cast steel was of the finest quality; the forging into the prismatic form was to show its malleability, for it was intended for the body of a gun to have a bore of 14 inches. Since the period referred to, ingots of more than 100 tons have been cast. That shown at Vienna was the product of some 1,800 crucibles, each containing 65 lbs. of melted steel, which had to be poured into the mould in a regular and continuous stream, so that the metal might solidify into a perfectly uniform mass. Such work can be done only by trained men, who act in regular ranks with military precision, and in pairs emptying their crucibles into channels previously assigned, then filing off to the other end of the rank to receive another crucible, while the pair of men who were behind are pouring out theirs, and so on in succession. The crucibles are emptied into a number of channels formed of iron lined with fire-clay, and leading down into the mould. Many precautions have to be taken to ensure the regular progress of the operations, and all the time required to fill the huge moulds may be counted by minutes.

The headpiece to our chapter on Fire-Arms gives but a very inadequate idea of the magnitude of the Essen Works about 1870. A better notion will be obtained from a few figures which we select from a list giving some of the contents of the Essen Works in 1876. There were 1,109 furnaces of various kinds, of which 250 were for smelting; 77 steam hammers, 294 steam engines, 18 rolling mills, 365 turning lathes, and 700 other machine tools; 24 miles of ordinary gauge railway for traffic within the works; together with 10 miles of narrow gauge railway; 38 miles of telegraph lines, with 45 Morse apparatus, etc. (J. S. Jeans’ _Steel: its History, etc._, 1880). These figures belong, be it observed, to the state of things in 1876; but we learn from a later authority that in 1894 these works employed 15,000 men, and we must suppose that the plant has been proportionately increased since the earlier period, when 10,000 men were employed.

In the year 1854 a regular system of records began to be kept of the amounts of coal and ores raised in Great Britain, and also of the quantities of the various metals produced. These show that in 1894 very nearly three times as much coal was raised as in 1854, and that in the same period the quantity of British pig iron smelted annually had increased four-fold; these increases look small when compared with the expansion of the steel production in Britain within the same period of forty years, for this had enlarged _thirty-fold_. This extraordinary development is attributable to the introduction of two processes by either of which various steels of excellent quality, and adapted to a great range of applications, can be produced cheaply and with certainty. These processes are respectively known as the Bessemer and the Open Hearth, and the reader should observe that with the main principles involved in these he has already been made acquainted.

Henry Bessemer, who first saw the light in England in 1813, may be said to have been born an inventor, for his father was one before him—a Frenchman employed in the royal mint at Paris, afterwards appointed by the Revolutionary authorities to superintend a public bakery; on an accusation of giving short weight, thrown into prison, from which, and probably from the guillotine, he escaped, and found employment in the English mint. Subsequently he devised some notable improvements in the art of producing letterpress type, and for many years carried on a prosperous business as a typefounder. The son developed inventive faculties at a very early age: in lathe engraving, dies, dating stamps, etc. His name became familiar to everyone by his production of the metallic powder long known as “Bessemer’s Gold Paint.” It became known to Bessemer that the raw material of this substance, which was then sold at £5, 10_s._ per lb., really cost only about one shilling per lb., and he set himself to discover its composition and mode of manufacture. He succeeded in this so well that he could produce the article at the insignificant cost of four shillings a pound, and his first order for a supply of it was at the rate of £4 per lb., and the business was continued, realising profits of something like 1,000 per cent. at first. For this article no patent was taken out, but Bessemer himself, assisted by two trustworthy workmen, carried on the manufacture in secret, and he some time afterwards rewarded the fidelity of his men by handing over the business to them as a free gift. Then he took out patents for improvements in the manufacture of oils, varnishes, sugar, plate glass, etc. Several of his machines for these purposes were shown at the London Exhibition of 1851. Bessemer is said to have obtained altogether some 150 patents, including those granted for inventions connected with our subject. He may be regarded as the type of the very fortunate inventor, since on the patents of the one process we are going to describe he ultimately obtained royalties to the value of more than £1,057,000, and this irrespective of profits derived from commercially working it himself.

At the time of the Crimean War, Bessemer had some experiments made at Vincennes with cylindrical projectiles he had devised for firing from smooth-bore guns, yet so as to impart to the projectile at the same time rotation about its axis. The experiments were successful, but it was pointed out that the guns of cast iron then in use would not bear heavy projectiles, and he was induced, at the suggestion of the Emperor Napoleon III., to undertake some researches with the view of finding metal more suitable for artillery. Bessemer, having then little knowledge of the metallurgy of iron, applied himself on his return to England to the study of the best books on the subject, visited the principal iron-working districts, and began a series of experiments at a small experimental installation he set up in London. There, after repeated failures, he did at length succeed in producing a metal much tougher than the cast iron then used, and a small model gun was submitted to the Emperor, who encouraged Bessemer to persevere with his experiments; which he did, though the expense was a great tax on his capital, continued as the experiments were for two years and a half. But by this time he had acquired a knowledge of many important facts, and these gradually led him to the experimental realization of the idea he had conceived, but only after many trials in which several thousand pounds were expended. At length the agenda of the British Association for the Cheltenham meeting of 1856 announced that a paper would be read by H. Bessemer, entitled “The Manufacture of Iron and Steel without Fuel.” It will be easily understood that a title in such terms would give rise to much derisive incredulity; and we may imagine the iron-masters on that occasion crowding into Section G, while asking each other in the spirit of certain philosophers of old, “What will this babbler say?” Some of what he did say may here be quoted, as at once explanatory and historically memorable.

“I set out with the assumption that crude iron contains about 5 per cent. of carbon; that carbon cannot exist at a white heat in the presence of oxygen without uniting therewith and producing combustion; that such combustion would proceed with a rapidity dependent on the amount of surface of carbon exposed; and lastly, that the temperature which the metal would acquire would be also dependent on the rapidity with which the oxygen and carbon were made to combine; and consequently, that it was only necessary to bring the oxygen and carbon together in such a manner that a vast surface should be exposed to their mutual action, in order to produce a temperature hitherto unattainable in our largest furnaces.

FIG. 23.—_Experiments at Baxter House._
]

“With a view of testing practically this theory, I constructed a cylindrical vessel of 3 ft. in diameter and 5 ft. in height, somewhat like an ordinary cupola furnace (see Fig. 23). The interior is lined with firebricks, and at about 2 in. from the bottom of it I inserted five _tuyère_ pipes, the nozzles of which are formed of well-burned fire-clay, the orifice of each _tuyère_ being about three-eighths of an inch in diameter; they are so put into the brick lining (from the outer side) as to admit of their removal and renewal in a few minutes, when they are worn out. At one side of the vessel, about half-way up from the bottom, there is a hole made for running-in the crude metal, and on the opposite side there is a tap-hole, stopped with loam, by means of which the iron is run out at the end of the process. In practice this converting vessel may be made of any convenient size, but I prefer that it should not hold less than one nor more than five tons of fluid iron at each charge; the vessel should be placed so near to the discharge hole of the blast furnace as to allow the iron to flow along a gutter into it. A small blast cylinder is required capable of compressing air to about 8 lbs. or 10 lbs. to the square inch. A communication having been made between it and the _tuyères_ before named, the converting vessel will be in a condition to commence work; it will however on the occasion of its first being used after re-lining with firebricks be necessary to make a fire in the interior with a few baskets of coke, so as to dry the brickwork and heat up the vessel for the first operation, after which the fire is to be all carefully raked out at the tapping-hole, which is again to be made good with loam: the vessel will then be in readiness to commence work, and may be so continued without any use of fuel until the brick lining, in the course of time, becomes worn away, and a new lining is required. I have before mentioned that the _tuyères_ are situated nearly close to the bottom of the vessel, the fluid metal will therefore rise some 18 in. or 2 ft. above them; it is therefore necessary, in order to prevent the metal from entering the _tuyère_ holes, to turn on the blast before allowing the fluid crude iron to run into the vessel from the blast furnace. This having been done, and the metal run in, a rapid boiling up of the metal will be heard going on within the vessel, the metal being tossed violently about and dashed from side to side, shaking the vessel by the force with which it moves; from the throat of the converting vessel flame will immediately issue, accompanied by a few bright sparks such as are always seen rising from the metal when running into the pig-beds. This state of things will continue for about fifteen minutes, during which time the oxygen in the atmospheric air combines with the carbon contained in the iron, producing carbonic oxide, or carbonic acid gas, and at the same time evolving a powerful heat. Now, as this heat is generated in the interior of, and is diffused in innumerable fiery bubbles through, the whole fluid mass, the metal absorbs the greater part of it, and its temperature becomes immensely increased, and by the expiration of the fifteen minutes before named that part of the carbon which appears mechanically mixed and diffused throughout the crude iron has been entirely consumed: the temperature however is so high that the chemically combined carbon now begins to separate from the metal, as is at once indicated by an immense increase in the volume of flame rushing out of the throat of the vessel. The metal in the vessel now rises several inches above its natural level, and a light frothy slag makes its appearance and is thrown out in large foam-like masses. This violent eruption of cinder generally lasts about five or six minutes, when all further appearance of it ceases, a steady and powerful flame replacing the shower of sparks and cinder which always accompanies the boil. The rapid union of carbon and oxygen which thus takes place adds still further to the temperature of the metal, while the diminished quantity of carbon present allows a part of the oxygen to combine with the iron, which undergoes combustion and is converted into an oxide. At the excessive temperature that the metal has now acquired, the oxide as soon as formed undergoes fusion, and forms a powerful solvent of those earthy bases that are associated with the iron; the violent ebullition which is going on mixes most intimately the scoria and metal, every part of which is thus brought in contact with the fluid oxide, which will thus wash and cleanse the metal most thoroughly from the silicon and other earthy bases which are combined with the crude iron, while the sulphur and other volatile matters which cling so tenaciously to iron at ordinary temperatures are driven off, the sulphur combining with the oxygen and forming sulphurous acid gas.

“The loss in weight of crude iron during its conversion into an ingot of malleable iron was found, on a mean of four experiments, to be 12½ per cent., to which will have to be added the loss of metal in the finishing rolls. This will make the entire loss probably not less than 18 per cent. instead of about 28 per cent., which is the loss on the present system. A large portion of this metal is however recoverable by heating with carbonaceous gases the rich oxides thrown out of the furnace during the boil. These slags are found to contain innumerable small grains of metallic iron, which are mechanically held in suspension in the slags and may be easily recovered.

“I have before mentioned that after the boil has taken place a steady and powerful flame succeeds, which continues without any change for about ten or twelve minutes, when it rapidly falls off. As soon as this diminution of flame is apparent the workman will know that the process is completed, and that the crude iron has been converted into pure malleable iron, which he will form into ingots of any suitable size and shape by simply opening the tap-hole of the converting vessel and allowing the fluid malleable iron to flow into the iron ingot moulds placed there to receive it. The masses of iron thus formed will be free from any admixture of cinder, oxide, or other extraneous matters, and will be far more pure and in a forwarder state of manufacture than a pile formed of ordinary puddle bars. And thus it will be seen that by a single process, requiring no manipulation or particular skill, and with only one workman, from three to five tons of crude iron pass into the condition of several piles of malleable iron in from thirty to thirty-five minutes, with the expenditure of about a third part the blast now used in a finery furnace, with an equal charge of iron, and with the consumption of no other fuel than is contained in the crude iron.

“To those who are best acquainted with the nature of fluid iron, it may be a matter of surprise that a blast of cold air forced into melted crude iron is capable of raising its temperature to such a degree as to retain it in a perfect state of fluidity after it has lost all its carbon and is in the condition of malleable iron, which, in the highest heat of our forges, only becomes softened into a pasty mass. But such is the excessive temperature that I am enabled to arrive at with a properly shaped converting vessel and a judicious distribution of the blast, that I am enabled not only to retain the fluidity of the metal, but to create so much surplus heat as to remelt all the crop-ends, ingot-runners, and other scrap that is made throughout the process, and thus bring them, without labour or fuel, into ingots of a quality equal to the rest of the charge of new metal....

“To persons conversant with the manufacture of iron, it will be at once apparent that the ingots of the malleable metal which I have described will have no hard or steely parts, such as are found in puddled iron, requiring a great amount of rolling to blend them with the general mass, nor will such ingots require an excess of rolling to expel cinder from the interior of the mass, since none can exist in the ingot, which is pure and perfectly homogeneous throughout, and hence requires only as much rolling as is necessary for the development of fibre; it therefore follows that, instead of forming a merchant bar, or rail, by the union of a number of separate pieces welded together, it will be far more simple and less expensive to make several bars or rails from a single ingot. Doubtless this would have been done long ago had not the whole process been limited by the size of the ball which the puddler could make.

“The facility which the new process affords of making large masses will enable the manufacturer to produce bars that, in the old mode of working, it was impossible to obtain; while at the same time it admits of the use of more powerful machinery, whereby a great deal of labour will be saved and the process be greatly expedited.... I wish to call the attention of the meeting to some of the peculiarities which distinguish cast steel from all other forms of iron, viz., the perfectly homogeneous character of the metal, the entire absence of sand-cracks or flaws, and its greater cohesive force and elasticity, as compared with the blister steel from which it is made,—qualities which it derives solely from its fusion and formation into ingots, all of which properties malleable iron acquires in like manner by its fusion and formation into ingots in the new process; nor must it be forgotten that no amount of rolling will give the blister steel, although formed of rolled bars, the same homogeneous character that cast steel acquires by a mere extension of the ingot to some ten or twelve times its original length....

“I beg to call your attention to an important fact connected with the new process which affords peculiar facilities for the manufacture of cast steel. At that stage of the process immediately following the boil the whole of the crude iron has passed into the condition of cast steel of ordinary quality. By the continuation of the process the steel so produced gradually loses its small remaining portion of carbon, and passes successively from hard to soft steel, and from soft steel to steely iron, and eventually to very soft iron; hence, at a certain period of the process, any quality of metal may be obtained. There is one in particular which by way of distinction I call semi-steel, being in hardness about midway between ordinary cast steel and soft malleable iron. This metal possesses the advantage of much greater tensile strength than soft iron; it is also more elastic, and does not readily take a permanent set, while it is much harder and is not worn or indented so easily as soft iron; at the same time it is not so brittle or hard to work as ordinary cast steel. These qualities render it eminently well adapted to purposes where lightness and strength are specially required, or where there is much wear, as in the case of railway bars, which from their softness and lamellar texture soon become destroyed. The cost of semi-steel will be a fraction less than iron, because the loss of metal that takes place by oxidation in the converting vessel is about 2½ per cent. less than it is with iron; but as it is a little more difficult to roll, its cost per ton may fairly be considered to be the same as iron; but as its tensile strength is some 30 or 40 per cent. greater than bar iron, it follows that for most purposes a much less weight of metal may be used than that so taken. The semi-steel will form a much cheaper metal than any we are at present acquainted with. These facts have not been elicited from mere laboratory experiments, but have been the result of working on a scale nearly twice as great as is pursued in our largest iron works, the experimental apparatus doing 7 cwt. in thirty minutes, while the ordinary puddling furnace makes only 4½ cwt. in two hours, which is made into six separate balls, while the ingots or blooms are smooth, even prisms, 10 in. square by 30 in. in length, weighing about equal to ten ordinary puddle balls.”

The startling novelty of the methods and results described in this paper had the effect of paralyzing discussion at the time. But soon the voice of detraction was heard; many iron-masters ridiculed the idea of producing iron and steel without fuel, and indeed it may have been observed, the title of the paper notwithstanding, that first the silicon and carbon, and then the iron itself, really supplied the fuel. And we must remember that malleable iron in a molten state was then deemed an impossibility, for the hottest furnaces then known could not effect the fusion, however prolonged their action might be, yet Bessemer was to obtain five tons in this condition in the short space of half an hour with no other aid than cold air. Then it was said that Bessemer’s process of forcing air into melted cast iron had no claim of novelty, for it had been tried before and found valueless. Some iron-masters on trying experiments on a small scale and with imperfect appliances met with failures, and discredited the process at once; but five large establishments paid for licences sums amounting to £26,500 within three weeks of the reading of the paper. At the works of the Dowlais Iron Co., in South Wales, who were the first licensees, the first converter was set up under Bessemer’s personal superintendence, and at the first operation five tons of iron were produced direct from the blast furnace pig. This apparently satisfactory result proved quite otherwise when this iron came to be practically tested; for it was found quite useless! It was both “_cold-short_” and “red-short,” to use the technical terms,—the former of which means that although the sample may be welded, it is when cold brittle and rotten; the latter means that at a low red heat it breaks and crumbles under the hammer. Further trials were made, new experiments instituted, but the success that attended Bessemer’s early experiments could not be repeated, and as yet no one knew the reason why. Now it so happened that in the preliminary experiments an exceptionally pure pig iron had been made use of containing little or no phosphorus or sulphur, substances very deleterious in iron, and still more so in steel. With the capital obtained by the sale of his licences Bessemer quietly set to work to investigate the cause of his non-success, making daily experiments with a ton or two of metal at a time. These experiments extended over a period of two and a half years, and upon them Bessemer and his partner spent about £16,000, besides the £4,000 the preliminary researches had cost. But all difficulties were at length overcome, and the process was now found capable of turning out pure iron and steel when the pure pig iron of Sweden was used in the converter. In the meantime the licensees had made no attempts practically to carry out the process, which began to be denounced as visionary: it was “a mare’s nest”; it was “a meteor that had passed through the metallurgical world, but had gone out with all its sparks.” When Bessemer again brought the subject before the public, he found that no one believed in it; everyone said, “Oh, this is the thing that made such a blaze two or three years ago, and which was a failure.” Neither iron-makers nor steel-makers would now take it up. Bessemer and his partner thereupon joined with three other gentlemen to establish at Sheffield a steel-works of their own, where the invention should be carried into full practice. In due time works were erected, and they commenced to sell steel, receiving at first very paltry orders, for such quantities as 28 lbs. or 56 lbs.; but the orders soon became larger, and afterwards very much larger, for they were underselling the Sheffield manufacturers by £20 a ton, and their steel was undistinguishable from the higher priced article. Bessemer had now bought his licences back again, and in the course of his second set of experiments had patented each improvement as it occurred to him, finally bringing the mechanical apparatus to the degree of efficiency requisite for practical working, without which his primary idea would have been valueless. Before directing the reader’s attention to the form the apparatus had assumed, we may transcribe what Mr. Jeans, in the work above referred to, has told about the commercial success of the Bessemer steel-making firm:—

“On the expiration of the fourteen years’ term of partnership of this firm the works, which had been greatly increased from time to time out of revenues, were sold by private contract for exactly twenty-four times the amount of the whole subscribed capital, notwithstanding that the firm had divided in profits during the partnership a sum equal to fifty-seven times the gross capital, so that by the mere commercial working of the process, apart from the patent, each of the five partners retired after fourteen years from the Sheffield works with eighty-one times the amount of his subscribed capital, or an average of nearly cent. per cent., every two months,—a result probably unprecedented in the annals of commerce.”

FIG. 24.—_Bessemer Converter._

A, Front view, showing the mouth, _c_; B, Section.
]

The form of the Bessemer apparatus as it finally left the inventor’s hands may now be considered: but in certain details and arrangements some modifications, dictated by the experience and requirements of individual establishments, have been made, leaving the principles of the apparatus unchanged. Thus instead of making the converting vessel turn on trunnions, it is sometimes constructed fixed, the fluid metal after conversion being let out at a tap-hole; the number and size of the _tuyères_ are varied; and so with the disposition of the air chamber or _tuyère_ box, the pressure of the blast, the capacity of the converter itself, etc. In capacity converters vary between 2½ tons and 10 tons; one of medium size is shown in elevation and section in Fig. 24, and may be described as an egg-shaped vessel about 15 ft. high and 6 ft. diameter inside. It is strongly made of wrought iron in two parts bolted together, and is lined inside with some thick infusible coating, of which more is to be said presently. The converter swings on trunnions, one of which is hollow, and admits the blast by the pipe _b_ to the base of the vessel, whence it passes through the passages shown at _e_. The thickness of the lining at _e_ may perhaps be 20 in., and passages for the air are perforated in fire-clay _tuyères_, of which there may be seven, each with seven perforations of half an inch diameter. To the other trunnion is attached a toothed wheel which engages the teeth of a rack receiving motion from hydraulic pressure. The iron for the operation is melted in a furnace having its hearth above the level of the converter; and to receive its charge the latter is turned so that the molten cast iron may be poured in from a trough until its surface is nearly on a level with the lowest of the _tuyères_. The blast having been turned on, the hydraulic power is set to work and the converter is slowly brought to an upright position. The pressure of the current of air prevents any of the fluid metal from entering the blow-holes. The blast of cold air is continued until all the silicon and carbon have been removed by oxidation. If the production is to be steel, there is then added to the contents of the converter, placed in position to receive it, a certain weight of melted cast iron of a special constitution, and the blow is resumed for a few minutes; or in more recent practice this special metal is added to the fluid metal run out of the converter into a spacious ladle in known quantity. On this addition an intense action takes place, attended by an extremely brilliant flame and a throwing out of cinder or slag. The metal thus added to the decarbonized iron is a carbonized alloy of iron and manganese obtained from an ore naturally containing the latter metal, and scarcely any phosphorus or sulphur. The charcoal pig from this ore is called _spiegeleisen_ (German = mirror-iron) from its brilliant reflecting facets; it contains from 12 to 20 per cent. of manganese, with about 5 per cent. of carbon, and a considerable proportion of silicon. An exact chemical analysis of the particular spiegeleisen having been previously made, it is known what proportion of it is to be added to the decarbonized iron in order to convert this into a steel with any required content of carbon. The manganese probably acts by combining with oxide of iron diffused through the mass, and together with the silicon forming the very easily separated slag which is ejected.

The whole series of operations connected with the Bessemer process may be easily followed by the help of Fig. 25, which is taken from a beautiful model in the Museum of Practical Geology. This model, which was presented to the museum by Mr. Bessemer himself, represents every part of the machinery and appliances of the true relative sizes. C is the trough, lined with infusible clay, by which the liquid pig iron is conveyed to the converters, A. The hydraulic apparatus by which the vessels are turned over is here below the pavement, but the rack which turns the pinion on the axis of the converter is shown at B. The vessel into which the molten steel is poured from the converter is marked E, and this vessel is swung round on a crane, D, so as to bring it exactly over the moulds, placed in a circle ready to receive the liquid steel, which on cooling is turned out in the form of solid ingots. The valves which control the blast, and those which regulate the movements of the converter through the hydraulic apparatus, are worked by the handle seen at H. The crane, or revolving table, D, is also under perfect control, so that the crude pig iron is converted into steel, and the moulds are filled with a rapidity and ease that are positively marvellous to a spectator.

FIG. 25.—_Model of Bessemer Steel Apparatus._
]

The development of the Bessemer process soon had the effect of so reducing the price of steel that this material came into use for almost every purpose for which iron had previously been employed, such as railway bars, girders, etc., for bridges, boiler plates, etc., for all which “steely iron” containing only 0·12 to 0·40 per cent. carbon proved admirably adapted. The practical success of the Bessemer process had not long been demonstrated commercially by the inventor and his partners at Sheffield before other firms began the manufacture: so that in 1878 there were in Great Britain alone twenty-seven establishments making Bessemer steel and using 111 converters. It may give an idea of the magnitude the Bessemer steel manufacture had attained even at that time if we quote the cost of erecting a complete plant for two 5–ton converters: it was £44,400, as given in a detailed estimate. In all these cases pig iron from ores free from phosphorus and sulphur had to be used, for as we have seen the converter failed to eliminate these vitiating elements. Imported pig ores had in general to be used, or pig from the limited supply of British hæmatite ores in West Cumberland. The Barrow Hæmatite Steel Company engaged in the production of Bessemer steel on a very large scale, having by 1878 erected no fewer than sixteen converters of the capacity of 6 tons each. In the meanwhile many efforts were made to discover some method of eliminating phosphorus, so that the ordinary qualities of British pig iron, and iron derived in any part of the world from the coarse phosphorized ores, might be available for the converter. Many of the methods then devised proved correct in principle and feasible in practice; but as, for sundry reasons, none of them came extensively into use, we need not here allude to them further.

The solution of the problem was announced in 1879. Some years before, G. J. Snelus had come to the conclusion that with a siliceous lining it would be impossible to eliminate phosphorus in the Bessemer converter, and that some refractory substance of a basic character must be sought for in order that the slag produced should be in a condition to absorb the phosphoric acid as fast as it is produced. He patented in 1872 the use of magnesian limestone as a material for the lining; as that substance when intensely heated became very hard and stony, being in that condition quite unaffected by water. Two young chemists, Messrs. Thomas and Gilchrist, apparently without being aware of Mr. Snelus’s conclusions, had also convinced themselves that the chief deficiency in the Bessemer process was due to the excess of silica in the slag, and in 1874 they began to try the effect of basic linings, and also of basic additions, such as lime, etc., to the charge in the converter, so that the lining itself should not be worn out by entering into the slag. Their results proved that phosphorus could be eliminated when the slag contained excess of a strong base. An example of an operation at Bolckow, Vaughan, & Company’s Eston works with the highly phosphorized Cleveland pig iron may be quoted. The basic-lined converter received first 9 cwt. of lime, then 6 tons of metal. When the blast at 25 lbs. pressure was turned on, the silicon began at once to burn; for three minutes the carbon was not affected, but for fourteen minutes longer it regularly diminished, the silicon keeping pace with it. After the blow had been continued for thirteen minutes from the commencement, the converter was turned down to allow of the further introduction of 19½ cwt. of a mixture of two parts of lime with one of oxide of iron. So long as 1·5 per cent. of carbon remained in the metal the phosphorus was untouched, and at the end of the blow, _i.e._ when the flame dropped, only one-third of it had been eliminated; it still formed 1 per cent. of the metal. The blast continued for another two minutes brought it down to ¼ per cent., and in one more minute only a trace was left. Most of the sulphur was got rid of at the same time. From Cleveland pig, thus de-phosphorized in the Bessemer converter, large quantities of steel rails were rolled for the North Eastern Railway Company, and were found entirely satisfactory, being as good as those made from the Cumberland hæmatite steel. This de-phosphorized process has been brought into operation wherever phosphoric ores are dealt with, and it has been applied with equal success in the “open hearth” furnaces, of which we have now to speak.

All discoveries and all inventions may be traced back to preceding discoveries and inventions in an endless series, and it is only by its precursors that each in its turn has been made possible. If we take one of the greatest marvels brought into existence at nearly the close of our epoch, namely, “wireless telegraphy,” we may follow up links of a chain connecting it with the recorded observations of an ancient Greek (Thales) who flourished seven centuries before our era, and even these may not have been original discoveries of his. And it will have been gathered from what has already been said that steel must have been produced, however unwittingly, at the earliest period at which man began to reduce iron from its ores. So the very latest, and for many purposes the most extensively practised, process of modern steel-making, brought indeed to working perfection mainly by the perseverance and scientific insight of two individuals, is the result of the observation and the accumulated experience of former generations. The observations and experience here alluded to are chiefly those that follow two lines: one concerning the properties of the metal itself, the other relating to the means of commanding very high temperatures on a great scale. On this occasion we are able almost to lay a finger on some proximate links of the chain. Réaumur, the French naturalist, made steel in the early part of the eighteenth century by melting cast iron in a crucible, and in this liquid metal he dissolved wrought iron, the product being, as the reader will now easily understand, the intermediate substance, steel; and this was obtained of course at a temperature which was incapable of fusing wrought iron by itself. He published in 1722 a treatise on “The Art of converting Iron into Steel, and of softening Cast Iron.” For this, and certain other metallurgical discoveries, Réaumur received a life-pension equivalent to about £500 per annum,—a treatment very different from that dealt out by the British to Henry Cort. The action in Réaumur’s crucible is precisely that used on the large scale in Siemens’ open hearth. But this last became possible only when Siemens had worked out his “regenerative stove” or heat accumulator, the development of an idea suggested by a Dundee clergyman in 1817.

A general notion of the Siemens’ regenerative stove will have been already gained from the account given before of its application to the modern type of blast furnace. Of the inventor himself, C. William Siemens, it may be observed that he was one of a family of brothers, all remarkable for their scientific attainments, and in many of his researches and processes he was aided by his brothers Frederick and Otto. In our article on “Electric Power and Lighting” there will be found some notice of a few of Siemens’ inventions pertaining to those subjects. A still more admirable invention of his is the electric pyrometer, an instrument of the utmost utility for measuring, with an accuracy previously unapproachable, the high temperature of furnaces, etc. Indeed there are few departments of science, pure or applied, which have not been enriched by the researches and contrivances of this distinguished man, whose merits were acknowledged by the bestowal upon him of the highest scientific and academical honours, and also of a title, for he became Sir William Siemens.

FIG. 26.—_Section of Regenerative Stoves and Open Hearth._
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Siemens was much engaged from 1846 in conjunction with his brother Frederick in experimental attempts, continued over a period of ten years, at the construction of the regenerative gas furnace. At length, in 1861, he proposed the application of his furnace to an “open hearth,” and during the next few years some partial attempts to carry out his process were made, and he himself had established experimental works at Birmingham in order to mature his processes, while Messrs. Martin of Sireuil, in France, having obtained licences under Siemens’ patents, gave their attention to a modification of his process, by which they succeeded in producing excellent steel. Siemens having in 1868 proved the practicability of his plans by converting at his Birmingham works some old phosphorized iron rails into serviceable steel, a company was formed, and in 1869 the Landore Siemens’ Steel Works were established at Landore in Glamorganshire, and a few years after, these had sixteen Siemens open hearth melting furnaces at work, giving a total output of 1,200 tons of steel per week. The number of furnaces was subsequently increased. Extensive works specially designed for carrying out the Siemens and the Siemens-Martin process were shortly afterwards erected at other places, as at Newtown, near Glasgow, Panteg in Wales, etc. In Great Britain the open hearth process gradually gained upon the Bessemer, until in 1893, when the total output of both kinds amounted to nearly 3,000,000 tons, this was almost equally divided between them, and since that period the steel made by the former has greatly surpassed in amount that made by the latter.

How the regenerative stove, or heat accumulator, works, and how it is applied in the open hearth process, the reader may learn by aid of the diagram Fig. 26, in which however no representation of the disposition of the parts in any actual furnace is given, nor any details of construction beyond what is necessary to make the principle clear. On the right and on the left of the diagram will be seen a pair of similar chambers which are shown as partly below the level of the ground S S´, such being a usual disposition. The outer walls of these chambers are thick and the interior is entirely lined with the most refractory fire-bricks, of which also is formed the partition in between each pair of compartments, as well as the passages from the top of each opening on the furnace H. Each chamber or compartment is filled with rows of fire-bricks, laid chequerwise so as to leave a multitude of channels between. At the bottom of the chamber on the left let us suppose atmospheric air to be admitted by the channels A, A, A, and a combustible gas which we may take to be a mixture of carbonic oxide with some hydrogen is admitted in the same way to the second compartment on the left through the passages G, G, G. Supposing the apparatus quite cold in the first instance, the gas would ascend into the furnace H as shown by the arrows, because it might be drawn by an up-draught in a chimney connected with the six chambers shown at the bottom of the right, and it would also tend to rise up into the space H by its lighter specific gravity, and there it could be set on fire, when a volume of flame would pass across to the right, a plentiful supply of air rushing in through the air chamber from A, A, A, and the products of the combustion, mainly hot carbonic acid gas and hot nitrogen gas, in passing through the right-hand chambers, would make the bricks in both compartments very hot after a time, for the current would divide itself between the two passages, as indicated by the divided arrow. We have not shown the valves by which the workman is able, by merely pulling a lever, to shut off the air supply from A, A, A, and of gas from G, G, G, and put these channels into direct communication with the up-draught chimney, at the same time supplying gas at G´, G´, G´, and air at A´, A´, A´. These rise up among the now heated bricks each in its own compartment, but mix where they enter the furnace H, now hot enough to set them on fire, and the gaseous products of combustion, hotter now than before, descend among the fire-bricks of the left-hand compartments, heating them in turn. After another period, say half an hour, the valves are again reversed, and again gas and air both heated burn in the space H, and their products supply still more heat to the right-hand compartments. And so the action may be continued with a great temperature each time produced by the combustion of the combining bodies at increasingly higher temperatures. Thus, if cold gas and air by combination give rise to 500° of heat, when the same combine, at say the initial temperature of 400°, the result would be a temperature of 900°; if burnt at this latter degree, then 900° + 500° would be reached, and so on. It would seem as if there were no limit to the temperatures obtainable in this way. But the nature of the materials of which the furnace is constructed imposes a limit, for even the most refractory matters yield at length, and the working would come to an end by the fusing of the brickwork. The diagram is a section through the length of the hearth (for it is usually oblong in plan), and the low arch above H being exposed to the fiercest heat, is formed of the most refractory “silica bricks,” that is, bricks made of coarsely ground silica held together with a little lime; yet this extremely resisting material is acted upon, and the arch has to be renewed every few months or sometimes weeks. The hearth itself is supported by massive iron plates, shown in the diagram by the thick lines, above which is laid a deep bed L, of quartz sand or ganister, or where required a _basic_ lining, beaten hard down, and forming a kind of basin with sides sloping down in all directions to a point immediately below the centre of the fire-brick door D, where is the aperture for tapping, stopped by a mixture of sand and clay until the metal is ready for drawing off, when it runs outside into an iron spout lined with sand and is received into the ingot moulds. B in the figure represents the “bath,” as it is called, of molten metal, which, in the larger furnaces, where 20 tons of metal is operated on at once, may occupy an area of 150 square ft.

It need hardly be mentioned that there has to be a certain adjustment between the volumes of air and of gas that pass into the regenerative stoves, in order that the best effect may be obtained. Besides the limit of temperature occasioned by the nature of the materials, there is a chemical reason why the regenerative stoves cannot increase the temperature indefinitely. It is noticed that when the temperature of the furnace has become very high indeed, the flame over the hearth assumes a peculiar appearance, being interrupted by dark spaces. These are attributable to what is called in chemistry “dissociation,”—in this case the dissociation of carbonic acid gas, which by the heat alone separates into carbonic oxide and oxygen gases. In the same way these gases refuse to combine if brought together heated beyond a certain temperature. This phenomenon of dissociation is a general one, for it is found that for any pair of substances there is a characteristic range of temperature above or below which they refuse to combine. The gas used in these stoves is either unpurified coal gas, or that produced by passing steam over red-hot coal or coke.

We have spoken of the Siemens and the Siemens-Martin open hearth processes. In the latter a charge of pig iron, say 1½ tons, is first melted on the hearth, then about 2 tons of wrought iron is added in successive portions, and in like manner nearly as much scrap steel (_i.e._ turnings, etc.), the final addition being half a ton of spiegeleisen containing 12 per cent. of manganese. A furnace of corresponding dimensions will allow of three charges every twenty-four hours. In the Siemens process it is not wrought iron or steel scrap that is mainly used to decarbonize the pig, but a pure oxide ore. This is thrown into the bath of molten metal in quantities of a few cwts. at a time, when a violent ebullition occurs. When samples of the metal and of the slag are found to be satisfactory, spiegeleisen or ferro-manganese is added, and the charge is cast. This process takes a rather longer time than the former, but gives steel of more uniform character. In both processes, phosphorus is oxidized at the high temperature attained and passes into the slag, which last floats of course on the molten metal and is from time to time tapped off as the action proceeds.

FIG. 26_a_.—_Rolling Mill._
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Fig. 26_a_ shows a rolling mill with what is called a “two-high” train for finishing bars by passing them between the grooves cut in the rolls to give the required section. The rolls in the illustration turn in one direction only, and therefore the bars after emerging from the larger grooves have to be drawn back over the machine and set into a smaller pair from the same side. This inconvenience is avoided in the “three-high train,” on which three rolls revolve, and the bars can be passed through them from one side to the other alternately. The celerity with which a glowing steel ingot is without re-heating converted into a straight steel rail 60 or 100 feet long, by passing a few times backwards and forwards between the rolls, is very striking. These rolls are made of solid steel, and in some cases have a diameter of 26 inches or more.

_IRON IN ARCHITECTURE._

Everyone knows how much iron is used in those great engineering structures that mark the present age, and of which a few examples will be described in succeeding articles. One other feature of the nineteenth century is the use of iron in architecture. Some have, indeed, protested against the use of iron for this purpose, and would even deny the name of architecture to any structure obviously or chiefly formed of that material. Stone and wood, they say, are the only proper materials, because each part must be wrought by hand, and cannot be cast or moulded; and further, iron being liable to rust, suggests decay and want of permanence, and these are characters incompatible with noble building. All this can rest only on a relative degree of truth—as, for instance, machinery is used to dress and shape both wood and stone, and the permanence of even the latter is as much dependent on conditions as that of iron. Iron used in architecture is hideous when applied in shapes appropriate only to stone; but when it is disposed in the way suggested by its own properties, and receives ornament suitable to its own nature, the result is harmonious and graceful, and the structure may display beauties that could be attained by no other materials. Be that as it may, the great and lofty covered spaces that are required for our railway stations and for other purposes could have been obtained only by the free use of iron, and everyone can recall to mind instances of such structure not devoid of elegance, in spite of the absence—the proper absence—of the Classic “orders” or Gothic “styles.” The first notable instance of the application of iron on a large scale was the erection of the “Crystal Palace,” in Hyde Park, for the great Exhibition of 1851. It was taken down and re-erected at Sydenham, and there it has become so well known to everyone that any description of it is quite unnecessary in this place.

As another conspicuous example of what may be done with iron, the Eiffel Tower at Paris may be briefly described.